Toggle switch



Nov. 12, 1963 R. o. WILEY 3,110,781

TOGGLE SWITCH Filed Jan. 7, 1958 2 Sheets-Sheet l i 6! 83 E 59 l3 1 77-, ,7] r

73 I as 89 I l L 87 39 I5 Fig.l.

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INVENTOR Roy 0. Wiley BYwizmLng AT TOR NEY Nov. 12, 1963 R. o. WILEY 3,110,731

TOGGLE SWITCH Filed Jan. 7, 1958 2 Sheets-Sheet 2 49 I 45 55 -s9 l5 Fig. 6.

United States Patent 3,110,781 TOGGLE SWITCH Roy 0. Wiley, Bridgeport, Conm, assignor to The Bryant Electric Company, Bridgeport, C0nn., a corporation of Connecticut Filed Jan. 7, 1958, Ser. No. 707,488 9 Claims. (Cl. 209-67) This invention relates to electrical switches and more particularly to the type of switches which are designated as miniature switches and commonly employed to control electrical circuits where space is limited.

An object of the invention is to provide an electrical switch in which a cover is held in place on a base without the use of separate or special fastening means.

Another object of the invention is to provide an electrical switch having a pivoted handle for moving a plunger which engages and moves a pivotally mounted moving contact.

Another object of the invention is to provide an electrical switch having a pivoted handle in which a biased plunger is pivotally and slidably movable to engage and move a movable contact.

Another object of the invention is to provide an improved electrical switch in which the movable contact is prevented from stopping at any position other than its two extreme on and off positions.

Another object of the invention is to provide an improved electrical switch having a pivoted handle with a recess therein, in which a biased plunger for operating the movable contact is both pivotally and slidably mounted and arranged so that the plunger is prevented from operating the contact at an intermediate overcenter position.

The invention, both as to structure and operation together with additional objects and advantages thereof, will be best understood from the following detailed description thereof when read in conjunction with the accompanying drawings.

-In said drawings:

FIGURE 1 is a vertical sectional view of a switch embodying the principles of the invention;

FIG. 2 is a top plan view of the switch with the cover removed;

FIG. 3 is an enlarged perspective view of the operating plunger;

FIG. 4 is an enlarged longitudinal sectional view of the movable contact means;

FIG. 5 is an enlarged transverse sectional view of the movable contact means; and

FIG. 6 is a sectional view similar to FIG. 1 but showing the handle and plunger in a partially operated position.

Referring to FIG. 1 of the drawings, the switch comprises a base 11 and a cover 13 both of molded insulating material, stationary contacts '15 and 17 disposed at opposite ends of the base 11, a movable bridging contact indicated generally at 19 and an operating handle 21.

The bridging contact 19 is generally U-shaped and is formed from any suitable resilient conducting material, such as copper or copper alloy and has a central plate 23 (FIGS. 4 and 5) and downwardly extending side portions 25 forming a pair of parallel disposed double ended switch blades 27 and 29 for cooperating respectively with the stationary contacts and 17. The central plate 23 is secured to an insulating contact carrier 31 by means of a mounting clip 24 having a pair of tabs 33 extending outwardly from opposed ends thereof. The mounting clip 24 is located to engage the under surface of the plate 23 so that the tabs 33 extend to the opposite side of the carrier 31 and are bent back against the carrier to securely hold the carrier, the plate and the mounting clip together. The opposite edges of the carrier 31 have integral guide extensions 35 (FIG. 2) extending into slots in the side walls 37 of the base 11 to keep the carrier 31 aligned. Pivotal support of the carrier is provided by the apex of inclined surfaces 55.

The stationary contacts -15 and 17 are supported in matching slots 39 in the side walls 37 and the base wall of the base 11 and are held in place by the cover 13. Each of the stationary contacts 15 and 17 is provided with a terminal screw 41 accessible through openings 43 in the end walls 45 of the base 11 for connecting the switch in an electrical circuit.

A center post 47 molded integral with the base 11 and extending upwardly therein has its upper end formed with downwardly diverging angular surfaces 49 which extend through a central opening 53 formed in the central portion of the carrier 31. The post 47 is also provided with the inclined surfaces or shoulders 55 for limiting the movement of the bridging contact 19.

The operating handle 21 is of molded insulating material and is pivotally mounted in the cover 13 by laterally extending integral trunnions 57 which extend into openings in the cover 13. The handle 21 is provided with an integral arcuate portion 59 which in any position of the handle 21 substantially closes an opening 61 in the cover '13 through which the handle 21 extends.

The cover 13, together with the handle 21, is assembled with the base 11 by first engaging an integral projection 63 on the right end of the cover 13 under a shoulder 65 in the right end wall 45 of the base 11 and then pressing the left end of the cover 13 downwardly into the base. After the cover 13 is placed at its closed position ears 71 formed integrally with the stationary contact 17 are bent laterally to the position shown in FIG. 1 thus locking the cover 13' in position. A tab 75 struck out from the portion 73 of the stationary contact 17 engages under a portion 77 of the base 11 to hold the stationary contact in place on the base 11.

A plunger 79 (FIGS. 1 and 3) is disposed in a bore 81 in the handle 21 and is biased downwardly by a spring 83 compressed between the end of the bore 81 and the enlarged cylindrical upper end 85 of the plunger 79. The bore 81 of the handle 21 is rectangular in cross section having a width substantially equal to the diameter of the cylindrical upper end 85 of the plunger 79 and a depth substantially equal to the thickness of the plunger 79, there being sufiicient clearance to permit free pivotal and longitudinal movement of the plunger within the bore in the plane of operation of the handle 21.

In the closed position of the switch, the rounded lower end 87 of the plunger 79 is biased by the spring 83 against the contact carrier 31 and a stop 89 integral with the base 11. It will be noted that the angle of the surfaces 49 is greater than the angle of the contact 19 and the carrier 31 in the position of rest. When the handle 21 is rotated counterclockwise from the on to the off position to open the switch, the wall of the bore 81 of the handle engages the side of the plunger 79 forcing the rounded lower end of the plunger to slide up the inclined surface 49 compressing the spring 83. As the plunger 79 moves up the inclined surface 49, which has a greater angle than that of the contact carrier 31, it is moved out of contact with the carrier 31 and does not engage the carrier 31 until the plunger 79 passes the apex of the surfaces 49. As soon as the plunger 79 passes the apex, the spring 83 snaps the plunger downwardly causing the end 87 thereof to engage the carrier 31 and snap the bridging contact 19 to the open contact position, the bridging contact being guided in its movement by slots 91 in ribs 93 in the base 11.

By making the angle of the surfaces 49 greater than the angle of the shoulders 55, which determines the position of rest of the bridging contact 19, the plunger 79 is caused to separate from the carrier 31 as it moves up the inclined surface 49 and does not again engage the carrier until after it has pased the apex of the surfaces 49. Since the plunger 79 moves out of contact with the carrier 31 the bridging contact 19 will remain in the closed position until the plunger 79 passes the apex of the post 47. If the handle 21 is moved counterclockwise in the opening direction to a point where the plunger 79 is to the left of and just short of the apex as shown in FIG. 6, and then is either released or moved back to the on position, the plunger will be moved back to the FIG. 1 position without having opened the contacts. If from the FIG. 6 position the handle 21 is moved very slightly toward the off position, the plunger 79 will pass the apex of the part 47, will flop over against the right wall of the bore 81 and be driven downwardly by the spring 83 to engage the carrier 31 and snap the bridging contact 19 to the open position. The action is the same when the handle 21 is manipulated to close the switch. It will thus be seen that in the event the handle 21 is not moved far enough in either direction to cause the plunger to move over the apex of the post 47, the force of the spring 83 will cause the handle 21 and the plunger 79 to return to their positions of rest without having disturbed the positions of the bridging contact 19.

While the invention has been illustrated as applied to a single pole, single-throw switch, it will be obvious that by providing an additional bridging contact on the carrier 31 and the necessary additional stationary contacts, a double pole, single-throw switch could be provided. The operating means of the invention is also susceptible of embodiment in single pole, double-throw switches and double pole-double throw switches all coming within the scope of the invention.

Having disclosed the invention in accordance with the provisions of the patent statutes, it is to be understood that various changes and modifications may be made in the structural details thereof without departing from the spirit of the invention.

I claim as my invention:

1. An electrical switch having a casing comprising a base and cover of insulating material, spaced stationary contacts, movable bridging contact means pivotally supported in said base, operating means for actuating said bridging contact means comprising a lever pivotally supported in said cover'and having a recess therein, a generally rigid plunger disposed in said recess and having pivot means thereon engaging said lever to permit pivotal movement of said plunger within said recess, a reduced portion on said plunger normally extending out of said recess, stored energy means biasing said plunger into engagement with said bridging contact means, and a projection on said base having inclined surfaces thereon engageable by said plunger on movement of said lever to cause said plunger to disengage said bridging contact, said stored energy means when said lever is moved a predetermined distance causing said plunger to engage and move said bridging contact means.

2. An electrical switch having a casing comprising a base and cover of insulating material, spaced stationary contacts, movable bridging contact means pivotally supported in said base and movable to two positions, operating means for actuating said bridging contact means to said two positions comprising a lever pivotally supported in said cover and having a recess therein, a generally rigid plunger disposed in said recess and having pivot means thereon engaging said lever to permit pivotal movement of said said plunger within said recess, a reduced portion on said plunger normally extending out of said recess, stored energy means biasing said plunger into engagement with said bridging contact means, said stored energy means when said lever is moved a predetermined distance causing said plunger to engage and move said bridging contact means to one of said two positions.

3. An electrical switch comprising a base and a cover of insulating material, stationary contact means, movable contact means, an operating handle having a recess therein and movable to actuate said movable contact means, a generally rigid plunger disposed in said recess having pivot means at one end thereof engaging said handle and a reduced portion at the other end, said recess being wider in the direction of operation of said handle than said reduced portion of said plunger, biasing means normally biasing said plunger into engagement with said movable contact means, means defining inclined surfaces which upon movement of said handle cause pivotal and longitudinal movement of said plunger relative to said handle to energize said biasing means and cause said plunger to disengage said movable contact means, and said biasing means upon predetermined movement of said handle causing said plunger to engage and move said movable contact means.

4. An electrical switch comprising a base and a cover of molded insulating material, stationary and movable contact means in said base, operating means for actuating said movable contact means, a projection on one end of said cover engaging under a portion of said base, and said stationary contact means having a portion engageable with the other end of said cover when said cover is in position to hold said cover in place.

5. An electrical switch comprising a base of insulating material, stationary contact means, movable contact means supported in said base, operating means for said movable contact means comprising a handle pivotally mounted on said base and having a recess therein, a generally rigid plunger disposed for longitudinal movement in said recess, spring means for urging said plunger against said movable contact means to move the latter into and out of engagement with said stationary contact means in response to movement of said handle, said plunger having pivotal means on the inner end thereof in engagement with said spring means and said plunger to permit pivotal movement of said plunger in said recess when said handle undergoes pivotal movement.

6. A wiring device comprising a base of insulating material, stationary contact means mounted in said base, a cover of insulating material, said cover having a projection at one end thereof engaging under a portion of said base, said stationary contact means including a portion engaging the other end of said cover to secure the latter to said base.

7. A wiring device comprising an open sided housing of insulating material, contact means located in said housing adjacent to one Wall thereof, a recess in said one wall extending inwardly toward the open side of said housing, said contact means having a portion thereof located in said recess, a cover of insulating material located to enclose the open side of said housing and having a projection thereon engaging under a portion of another wall of said base, and said contact means having another portion thereon engaging the portion of said cover adjacent said one wall to hold said cover in place.

8. A wiring device comprising a base and a cover of insulating material, a stationary terminal and movable contact means, means for holding said terminal inwardly of said base and for supporting said movable contact means relative to said base, operating means for said movable contact means comprising a handle pivotally mounted on said cover and having a recess therein, said cover having a projection at one end thereof being engaged against and under a portion of said base, said stationary terminal including a portion engaging the other end of said cover to secure the latter relative to said base, said terminal portion being so located on said terminal as to enable said handle to be positioned by said cover for operating said movable contact means, a plunger disposed for longitudinal movement in said handle recess and biased to engage said movable contact means to move the latter into and out of engagement with said terminal in response to movement of said handle, said plunger having pivotal means on the inner end thereof to enable said plunger to move pivotally in said handle recess.

9. A wiring device comprising a base and a cover of insulating material, a stationary terminal and movable contact means, means for holding said terminal inwardly of said base and for supporting said movable contact means relative to said base, said holding means including a tab deflected outwardly of said terminal against a base portion Which is so positioned as to hold said tab and said terminal inwardly of said base, operating means for said movable contact means comprising a handle pivotally mounted on said cover and having a recess therein, said cover having a projection at one end thereof being engaged against and under a portion of said base, said stationary terminal including a portion engaging the other end of said cover to secure the latter relative to said base, said terminal portion being so located on said terminal as to enable said handle to be positioned by said cover for operating said movable contact means, a plunger disposed for longitudinal movement in said handle recess and biased to engage said movable contact means to move the latter into and out of engagement With said terminal in response to movement of said handle, said plunger being generally rigid and having pivotal means on the inner end thereof to enable said plunger to move pivotally in said handle recess.

References Cited in the file of this patent UNITED STATES PATENTS Lapaugh May 21, Meuer Apr. 17, Krieger Aug. 11, Douglas Oct. 5, Krieger Dec. 23, Johansson Oct. 14, Dupre Feb. 7, Johnson Mar. 13, Baak July 3, Ericson Sept. 4, Kelto Oct. 2, Greenbaum Oct. 30, Slater June 11, Seeger June 25, Taylor Aug. 6, Norden Oct. 29, Brand Jan. 20, Bussman Mar. 31, Benander et al.- Aug. 18, Bates Sept. 20,

FOREIGN PATENTS Italy Jan. 26, Great Britain June 27,

Germany May 29, 

1. AN ELECTRICAL SWITCH HAVING A CASING COMPRISING A BASE AND COVER OF INSULATING MATERIAL, SPACED STATIONARY CONTACTS, MOVABLE BRIDGING CONTACT MEANS PIVOTALLY SUPPORTED IN SAID BASE, OPERATING MEANS FOR ACTUATING SAID BRIDGING CONTACT MEANS COMPRISING A LEVER PIVOTALLY SUPPORTED IN SAID COVER AND HAVING A RECESS THEREIN, A GENERALLY RIGID PLUNGER DISPOSED IN SAID RECESS AND HAVING PIVOT MEANS THEREON ENGAGING SAID LEVER TO PERMIT PIVOTAL MOVEMENT OF SAID PLUNGER WITHIN SAID RECESS, A REDUCED PORTION ON SAID PLUNGER NORMALLY EXTENDING OUT OF SAID RECESS, STORED ENERGY MEANS BIASING SAID PLUNGER INTO EN- 